More Microwave Metal Casting

April 16, 2024 by Dan Maloney 10 Comments

If you think you can’t do investment casting because you don’t have a safe place to melt metal, think again. Metal casting in the kitchen is possible, as demonstrated by this over-the-top bathroom hook repair using a microwave forge.

Now, just because it’s possible doesn’t mean it’s advisable. There are a lot better ways to fix something as mundane as a broken bathroom hook, as [Denny] readily admits in the video below. But he’s been at the whole kitchen forging thing since building his microwave oven forge, which uses a special but easily constructed ceramic heat chamber to hold a silicon carbide crucible. So casting a replacement hook from brass seemed like a nice exercise.

The casting process starts with a 3D-printed model of the missing peg, which gets accessories such as a pouring sprue and a thread-forming screw attached to it with cheese wax. This goes into a 3D-printed mold which is filled with a refractory investment mix of plaster and sand. The green mold is put in an air fryer to dry, then wrapped in aluminum foil to protect it while the PLA is baked out in the microwave. Scrap brass gets its turn in the microwave before being poured into the mold, which is sitting in [Denny]’s vacuum casting rig.

The whole thing is over in seconds, and the results are pretty impressive. The vacuum rig ensures metal fills the mold evenly without voids or gaps. The brass even fills in around the screw, leaving a perfect internal thread. A little polishing and the peg is ready for bathroom duty. Overly complicated? Perhaps, but [Denny] clearly benefits from the practice jobs like this offer, and the look is pretty cool too. Still, we’d probably want to do this in the garage rather than the kitchen.
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A Look Inside A 70-GHz Electromechanical Attenuator

March 15, 2024 by Dan Maloney 4 Comments

It might not count as “DC to daylight,” but an electromechanical attenuator that covers up to 70 GHz is pretty close, and getting a guided tour of its insides is quite a treat.

Perhaps unsurprisingly, this one comes to us from [Shahriar] at “The Signal Path,” where high-end gear most of us never get a chance to work with goes for one last hurrah after it releases the magic smoke. And indeed, that appears to be exactly what happened to the Rohde & Schwarz 75 dB step attenuator, a part that may have lived in the front end of one of their spectrum analyzers. As one would expect from such an expensive component, the insides have some pretty special engineering. The signal is carried through the five attenuation stages on a narrow strip of copper. Each stage uses a solenoid to move the strip between either a plain conductor or a small Pi pad with a specified attenuation. The attention to detail inside the cavity is amazing, with great care taken to maintain the physical orientation of the stripline to prevent impedance mismatches and unwanted reflections.

The Pi pads themselves are fascinating, too, especially under [Shahriar]’s super-duper microscope. All of them were destructively removed from the cavity before getting to him, but it’s still pretty clear what’s going on. That’s especially true with the 5-dB pad, which bears clear signs of the overload that brought on the demise of the whole attenuator. We suppose a repair would have been feasible if it had been just the one pad that needed replacement, but with all of them broken, it’s off to the scrap bin. Or to the recycler — there appears to be plenty of gold in there.

We thought this was a fantastic look under the covers of an exquisitely engineered part. Too bad it didn’t rate the [Shahriar] X-ray treatment, as this multimeter repair or this 60-GHz phased array did. Oh, well — maybe next time.

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Hack Makes Microwave Cookies Fast And Not Terrible

March 11, 2024 by Dan Maloney 35 Comments

Making a chocolate chip cookie is easy. Making a good chocolate chip cookie is a little harder. Making a good chocolate chip cookie quickly is a pretty tall order, but if you cobble together a microwave and a conventional oven, you just might get delicious and fast to get together.

The goal of this Frankenstein-esque project is to build a vending machine that can whip up a fresh-baked chocolate chip cookie on demand and make [Chaz] wealthy beyond his wildest dreams. We’re guessing at that last part; for all we know his goal is world peace through instant cookies. We’re fine with the idea either way, and his previous work on the project resulted in a semi-automatic cookie gun to splooge the dough out in suitable dollops.

The current work is turning those into something edible, for which a microwave seems a logical choice. Experience tells us otherwise, so off to the thrift store went [Chaz], returning with a used air fryer. He ripped the guts out of a small microwave, slapped the magnetron onto the side of the air fryer, and discovered that this was officially A Bad Idea™ via a microwave leakage tester. Round 2 went the other way — adding a conventional heating element to a large microwave. That worked much better, especially after close-up video revealed the dynamics of microwave cookery and the best way to combine the two cooking modalities. The result is a contraption that makes a pretty tasty-looking two-minute cookie. World peace, here we come!

Of course there’s plenty to say about the safety of all this, much of which [Chaz] himself cops to in the video. It’s important to remember that he’s just prototyping here; we’re sure the final machine will be a little more sophisticated than a heat gun duct-taped to the side of a microwave. Those cookies aren’t going to bake themselves, though, so you’ve got to start somewhere.

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A red hot crucible is held with metal tongs above a white plaster mold. The mold is held in a bright pink silicone sleve atop a metal pan on a wooden workbench. Red cheese wax holds the sleeve to a metal funnel connected to a vacuum cleaner.

Lost Print Vacuum Casting In A Microwave

March 2, 2024 by Navarre Bartz 14 Comments

Hacks are rough around the edges by their nature, so we love it when we get updates from makers about how they’ve improved their process. [Denny] from Shake the Future has just provided an update on his microwave casting process.

Sticking metal in a microwave certainly seems like it would be a bad idea at first, but with the right equipment it can work quite nicely to develop a compact foundry. [Denny] walks us through the process start to finish in this video, including how to build the kilns, what materials to use, and how he made several different investment castings using the process. The video might be worth watching just for all the 3D printed tools he’s built to aid in the process — it’s a great example of useful 3D prints to accompany your fleet of little plastic boats.

A lot of the magic happens with a one minute on and six minutes off cycle set by a simple plug timer. This allows a more gradual ramp to burn out the PLA or resin than running the microwave at full blast which can cause some issues with the kiln, although nothing catastrophic as demonstrated. Vacuum is applied to the mold with a silicone sleeve cut from a swimming cap while pouring the molten metal into the mold to draw the metal into the cavities and reduce imperfections.

We appreciate the shout out to respirators while casting or cutting the ceramic fiber mat. Given boric acid’s effects, [PDF] you might want to use safety equipment when handling it as well or just use water as that seems like a valid option.

If you want to see where he started check out this earlier version of the microwave kiln and how he used it to make an aluminum pencil.

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Tech In Plain Sight: Microwave Ovens

September 26, 2023 by Al Williams 31 Comments

Our homes are full of technological marvels, and, as a Hackaday reader, we are betting you know the basic ideas behind a microwave oven even if you haven’t torn one apart for transformers and magnetrons. So we aren’t going to explain how the magnetron rotates water molecules to produce uniform dielectric heating. However, when we see our microwave, we think about two things: 1) this thing is one of the most dangerous things in our house and 2) what makes that little turntable flip a different direction every time you run the thing?

First, a Little History

Westinghouse Powercaster which could, among other things, toast bread in six seconds

People think that Raytheon engineer Percy Spenser, the chief of their power tube division, noticed that while working with a magnetron he found his candy bar had melted. This is, apparently, true, but Spenser wasn’t the first to notice. He was, however, the first to investigate it and legend holds that he popped popcorn and blew up an egg on a colleague’s face (this sounds like an urban legend about “egg on your face” to us). The Raytheon patent goes back to 1945.

However, cooking with radio energy was not a new idea. In 1933, Westinghouse demonstrated cooking foods with a 10 kW 60 MHz transmitter (jump to page 394). According to reports, the device could toast bread in six seconds. The same equipment could beam power and — reportedly — exposing yourself to the field caused “artificial fever” and an experience like having a cocktail, including a hangover on overindulgence. In fact, doctors would develop radiothermy to heat parts of the body locally, but we don’t suggest spending an hour in the device.

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The Device That Won WW2: A History Of The Cavity Magnetron

August 28, 2023 by Adam Fabio 55 Comments

[Curious Droid] is back with a history lesson on one of the most important inventions of the 20th century: The cavity magnetron. Forged in the fighting of World War II, the cavity magnetron was the heart of radar signals used to identify attacking German forces.

The magnetron itself was truly an international effort, with scientists from many countries providing scientific advances. The real breakthrough came with the work of [John Randall] and [Harry Boot], who produced the first working prototype of a cavity magnetron. The device was different than the patented klystron, or even earlier magnetron designs. The cavity magnetron uses physical cavities and a magnetic field to create microwave energy. The frequency is determined by the size and shape of the cavities.

While the cavity magnetron had been proven to work, England was strapped by the war effort and did not have the resources to continue the work. [Henry Tizzard] brought the last prototype to the USA where it was described as “the most valuable cargo ever brought to our shores”. The cavity magnetron went on to be used throughout the war in RADAR systems both air and sea.

Today, many military RADAR systems use klystrons or traveling wave tube amplifiers due to requirements for accurate frequency pulses. But the cavity magnetron still can be found in general and commercial aviation RADAR systems, as well as the microwave ovens we all know and love.

Check the video out after the break.

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Ku-Go: The World War II Death Ray

August 11, 2023 by Al Williams 66 Comments

Historians may note that World War II was the last great “movie war.” In those days, you could do many things that are impossible today, yet make for great movie drama. You can’t sneak a fleet of ships across the oceans anymore. Nor could you dig tunnels right under your captor’s nose. Another defining factor is that it doesn’t seem we seek out superweapons anymore.

A Churchill Bullshorn plough for clearning minefields — one of Hobart’s “Funnies”

Sure, we develop better planes, tanks, submarines, and guns. But we aren’t working on anything — that we know of — as revolutionary as a rocket, an atomic bomb, or even radar was back in the 1940s. The Germans worked on Wunderwaffe, including guided missiles, jets, suborbital rocket bombers, and a solar-powered space mirror to burn terrestrial targets. Everyone was working on a nuclear bomb, of course. The British had Hobart’s Funnies as well as less successful entries like the Panjandrum — a ten-foot rocket-driven wheel of explosives.

Death Ray

Perhaps the holy grail of all the super weapons — both realized and dreamed of was the “death ray.” Of course, Tesla claimed to have one that didn’t use rays, but particles, but no one ever successfully built one and there was debate if it would work. Tesla didn’t like the term death ray, partly because it wasn’t a ray at all, but also because it required a huge power plant and, therefore, wasn’t mobile. He envisioned it as a peacekeeping defensive weapon, rendering attacks so futile that no one would dare attempt them.

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